Container Closure With Segmented Fusion Ring

ABSTRACT

A container provides sealed storage for contents. The container includes a composite top member formed of a panel and a frame. The panel includes an opening for providing access to the contents of the package. The frame includes a closure member that is molded in an open position, and which can be moved to a closed position for closing the opening in the panel. The container is formed of a container body in the form of a tubular member formed to a desired shape. The container body is closed using the top member that closes a top opening of the container body, and a bottom member that closes a bottom opening of the container body.

BACKGROUND OF THE INVENTION

The present invention is generally related to providing protection forvarious products such as foods, drugs, chemicals and other products,including dry, semi-moist and liquid products as well as products whichcontain particulate of varying sizes and shapes.

The methods used to package and protect foods, drugs and chemicals todayinclude cans, bottles, jars, laminated canisters, and pouches as well assemi-rigid plastic containers. Additionally, most food, beverage andpharmaceutical products require more product protection that can beachieved by a single polymeric material. It is known that differentcombinations of materials can be used together to achieve desiredprotection in the areas of gas, moisture, chemical and thermalresistance properties, as well as physical properties that cannot beachieved economically by other means. In some instances, the desiredproperties can be achieved by a physical blend of various materials,such as Dupont Sclair™films which are an alloy or blend of nylon andpolyethylene used in the packaging of fluid milk and other foodproducts. Recently, inorganic nano sized particles have been found tomake significant improvements in the gas barrier properties of mostpolymers in which they are dispensed (see, e.g., JP 89308879.9). Bythemselves, these alloys have been useful in providing some additionalshelf life for refrigerated products or for products that are fairlytolerant of oxygen.

In some instances, nano particles have been used in conjunction withoxygen scavengers to improve the gas barrier of the carrier polymer andprovide a source of moisture for an anti-oxidant of the oxygen scavengerthat make up the alloy (see, e.g., JP 63281964). These blends, whichcontain both an oxygen scavenger and inorganic platelets to create atortuous path, are an improvement but do not, by themselves, provide thecost nor esthetics and continuing protection required for extended shelflife or shelf image of most oxygen intolerant, shelf stable foods andother products.

For critical packaging requirements of this type, the solution had beento package products in metal cans or glass jars. This solution endureduntil the development of semi-rigid, multi-layer, high-barrier plastics,which were commercialized in the mid 1980's in packaging for suchproducts as puddings, fruit compotes and single serve entrees.Previously, multi-layer, adhesive laminated, high-barrier thermoformedsheet technology had been used for small containers to package jams andjellies for single-serve, ready to use packs. These packs were producedbased upon aqueous coating technology utilizing Poly-Vinylidene Chloride(PVDC). The PVDC coating, while very effective in a flat film form, isnot capable of being stretched more that 10% without breaking apart.This prevents aqueous PVDC coatings from being used for larger sized ordeeper packages. To overcome extensibility problems, further developmentresulted in an extrudable version and a method of combining it in alaminar method through a process known as coextrusion, as disclosed inU.S. Pat. No. 3,557,265.

Coextrusion was used in the creation of packages for both high and lowacid foods, with the first publicized application of “plastic cans”being thermally processed (retorted) in the mid-1970's. “Plastic cans”are prevalent today, and are typically produced using a process known assolid-phase pressure-forming and, more recently, using multi-layeredinjection blow molding and/or extrusion blow molding processes. Thisprocess was developed in the early 1970's in an effort to create salesopportunities for a newly commercialized plastic polymer known aspolypropylene. Johnson U.S. Pat. No. 3,546,746 teaches that plasticarticles can be thermoformed not only from flat sheets but also frompre-cut shapes called billets or blanks. U.S. Pat. No. 3,502,310 toCoffman demonstrates an improved process involving heating the billetscontinuously and forming several articles simultaneously.

The primary advantage of forming articles and specifically containersfrom pre-formed plastic billets did not become obvious until the mid1980's when multi-layered plastic sheeting began to be used for thepackaging and preserving of processed shelf stable foods. Plasticbarrier containers have now become common and the primary methods ofproducing containers for shelf-stable applications are described below.

In a representative process, adhesively laminated or coextruded sheet isweb or sheet fed through a radiant or contact heating oven and thenthermoformed into its final shape by means of vacuum and/or pressure,with an additional assist from a movable plug to help distributematerial for deep or tall containers, where required. Containers arethen trimmed out of the web or sheet by trim tooling, which can eitherbe a trim in place style which removes the part from the web as part ofthe forming process, or an off-line style in which parts can be trimmedout of the web or sheet in a secondary trimming process. Web scrapgenerated in this process typically exceeds 40% of the total web used inthe process, and is not uncommon to see scrap losses of 50% on roundcontainer shapes. This high percentage of scrap increases the cost ofthe finished parts, since not all of the scrap can be recovered. Inaddition, the recoverable portion of the scrap is valued only at thecost of the lowest priced material in the web, since the only real valueof such material is as a structural component. The benefit of the moreexpensive barrier materials is lost when the web skeleton is ground upto make regrind.

To maintain the barrier characteristics of the original individuallayers or phases of the laminated sheet, each individual material mustmaintain its individual integrity. Grinding the web skeleton intoregrind destroys the integrity of the individual layers. The resultingblended materials, when extruded into a sheet, have none of the gasbarrier characteristics of the original multilayered sheet and in factwill have lost some of the physical properties of the initial structuralmaterial used in the original sheet manufacture. Additionally, some ofthe components in the original multilayered sheet are typically approvedfor indirect food contact only in high temperature food processingconditions. Because these materials are no longer sandwiched into thecenter portion of the sheet, it becomes necessary to place a separatefood contact layer between the regrind component and the food product toinsure that the materials, which are only acceptable for indirect foodcontact, are kept in that position.

In addition, if the initial multilayered sheet was clear, the use ofregrind will diminish the clarity in direct proportion to the amount ofregrind being used in the sheet. For containers which contain bothpolypropylene and EVOH (EVOH @ 1.5% or more), it has been commerciallydemonstrated that structures which incorporate web scrap of 15% or moreare noticeably cloudy and at levels of 20% become unacceptable for mostapplications. The web skeleton that is not recovered and reused backinto the manufacture of sheet is then sold off as waste, with a salvagevalue less than half that of the reused regrind, further increasing thecost of the original parts produced from the web.

Reduced scrap thermoforming has been developed to a commercial state inthe U.S. by two patented methods, the first being a scrapless formingprocess as shown in U.S. Pat. No. 3,947,204, and the second being abillet forming process as shown in U.S. Pat. Nos. 3,502,310; 3,546,746;and 3,538,997. Both methods incorporate process benefits described byBriston, et al., in PLASTICS IN CONTACT WITH FOODS, 466 pages, receivedin the PTO scientific library Dec. 31, 1974, as well as the processimprovements for transporting the billets identified in Frados et al.,PLASTICS ENGINEERING HANDBOOK, ISBN 0-442-22469-9, Library of CongressCatalog Card Number 75-26508 pages 315 & 316, describing theHoffco/Beloit Forming System. The original forming processes alsobenefited from the teachings of U.S. Pat. No. 3,538,997, which disclosesthe individual transportation of the billets through the oven and intothe forming station wherein the carrier becomes a central part of theforming tool. Once formed, the carrier tray transports the finishedparts to the removal station and begins the cycle again. This process isadapted in Parkinson U.S. Pat. No. 4,836,764.

Plastic containers used in the packaging of shelf stable foods requirednot only adequate barrier to prevent the oxidation of the productscontained within the package, but also had to prevent the gain or lossof moisture as well. As discussed, it is possible to design amultilayered package with the required barrier properties. However, theclosures for these types of packages require a different approach ormethod so as to allow easy access to the product. Initially, metallicfoils laminated and/or extrusion coated with polymeric thermal sealingcompounds were developed to provide controllable seal strengths for easeof opening. In order to utilize these flexible-sealing membranes, asealing surface or flange had to be designed into the package. Thesesealing surfaces typically were flat, although some exceptions werefound to be workable such as that created by Embro and disclosed in U.S.Pat. No. 4,282,699.

Metal can ends have also been used to seal these newer plasticcontainers with some success. However the can ends require that theplastic container have a flange, which is approximately 0.021″ thick.However, the starting thickness of the sheet is typically greater that0.080″ and can be as thick as 0.115″. The required thickness of theplastic container flanges thus necessitates that the sheet besignificantly reduced in thickness in order to meet the specificationsof the metal end. Reducing the sheet thickness to this degree typicallycreates interlayer adhesion and other problems. Interlayer adhesion ofthe compression molded double seamable flange can cause operationalproblems if the problems are not caught before they appear on theproduction floor. Additionally, the cut edge exposes the hydroscopicbarrier materials to a high level of moisture pickup, therebydiminishing its barrier properties.

It is an object of the present invention to provide a product packagethat overcomes the above-noted problems with prior art packages. It is afurther object of the invention to provide a multi-component productpackage that can be formed in various shapes and sizes, and is notlimited to use of round mating surfaces as in the prior art. Anotherobject of the invention is to provide a product package providing a sealof high integrity between the body and the end members of the package. Astill further object of the invention is to provide a product packagethat can be efficiently manufactured with minimal waste using acontainer body closed by a pair of end members. Another object of theinvention is to provide a product package that has the same relative orimproved amount of product protection as prior art packages, whileconsuming much less energy in the comparative total life cycle. A stillfurther object of the invention is to provide a product package in whichthe container body can be contoured according to manufacturer or userrequirements. Yet another object of the invention is to provide aproduct package having a reclosable opening to provide access to thecontents of the package, and which provides convenience in opening,dispensing and re-closing the package. A further object of the inventionis to provide a product package that is capable of efficient and rapidmass production, to provide a lower cost package than is currentlyavailable for barrier property containers. A still further object of theinvention is to provide a product package that is relatively inexpensiveto manufacture, yet which provides improved barrier characteristics andflexibility in package design over prior art packages.

SUMMARY OF THE INVENTION

In accordance with the present invention, a product package or storagecontainer includes a container body having an interior and including anupper edge defining an upper opening and a lower edge defining a loweropening. The storage container further includes a top member bonded tothe upper edge to enclose the upper opening, and a bottom member bondedto the lower edge to enclose the lower opening. The top member includesa top member opening to provide access to the interior of the containerbody. The top member includes a panel, and the top member opening is inthe form of an opening in the panel. The top member further includes aframe adapted for use in securing the top member to the upper edgedefined by the container body, and the frame includes a peripheral outerarea. The opening in the panel member is located inwardly of theperipheral outer area of the frame. In a preferred embodiment, the topmember and the bottom member each include a fusion member for use inbonding the top member and the bottom member to the upper edge and thelower edge, respectively, of the container body. Each fusion member iscontained within a channel defined by one of the top and bottom members.The channel defined by the top member is configured to receive the upperedge of the container body, and the channel defined by the bottom memberis configured to receive the lower edge of the container body. Eachfusion member is formed of a material that is responsive to externallyapplied energy, such as radio frequency (RF) energy or anelectromagnetic field. Exposure of the fusion member to the externallyapplied energy, such as RF energy or an electromagnetic field, resultsin non-contact application of the fusion member to such energy thatheats the material of the fusion member to cause the fusion member tobond with the edge of the container body. Each fusion member ispreferably injection molded into a peripheral edge portion, such as achannel portion, of each end member. The fusion member may be injectionmolded into the channel portion of the end member simultaneously withinsert molding the panel into the peripheral edge portion of the endmember.

The container body is preferably in the form of a tubular member formedof deformable material. The tubular member may be configured to define acontoured wall that is shaped in a forming operation carried out priorto bonding the top member and the bottom member to the container body.The forming operation includes sealing the top and bottom openings ofthe tubular member, placing the tubular member in a pliable state, andsubjecting the interior of the tubular member to internal pressure thatapplies an outward force to the wall or by creating a vacuum between theexterior wall of the tube and the surface of the mold, or a combinationof both forces acting upon the interior and exterior surfaces of thepliable tube walls. The tubular member is contained within a mold havingcontoured surfaces that contact the pliable wall of the tubular memberas the wall is moved outwardly, to form the contoured wall when theinterior of the tubular member is subjected to internal pressure. Theacts of sealing the top and bottom openings of the tubular member arecarried out by engaging top and bottom seal members with the top andbottom edges of the container body, respectively, and the act ofsubjecting the interior of the tubular member to internal pressure maybe carried out by applying a pressurized gas to the interior of thetubular member through one of the top and bottom seal members.

This aspect of the invention also contemplates a method of making acontainer, substantially in accordance with the foregoing summary.

In accordance with another aspect of the invention, a storage containerincludes a container body having one or more sides, an upper edgedefining an upper opening, and a bottom; in combination with a topmember secured to the upper edge and configured to enclose the upperopening. The top member includes an interior panel having a panelopening, and a removable seal member that encloses the panel opening.The top member further includes a movable closure member that isinterconnected with the top member so as to provide movement of theclosure member between an open position for exposing the panel openingwhen the removable seal member is removed, and a closed position inwhich the movable closure member overlies and closes the panel opening.The top member includes a frame to which the interior panel is bonded,and the frame includes means for bonding the frame to the upper edge ofthe container body. The means for bonding the frame to the upper edge ofthe container body is preferably in the form of a fusion ring, asdescribed previously. In a preferred form, the interior panel defines aperipheral edge area, and the interior panel is insert molded duringformation of the frame. The frame is configured to surround theperipheral edge area of the interior panel.

The movable closure member is formed along with the frame, and ispreferably interconnected with a platform area of the frame thatoverlies the panel opening. In the open position, the movable closuremember overlies an area of the interior panel adjacent the panelopening. Release means, in the form of a release agent, is interposedbetween the interior panel and the movable closure member for preventingthe movable closure member from adhering to the interior panel duringformation of the movable closure member. The movable closure member mayinclude a tab member adapted for manual engagement by a user tofacilitate movement of the movable closure member between the open andclosed positions. The interior panel includes a recess, and the tabmember at least partially overlies the recess to enable manualengagement of the tab member from within the recess.

The movable closure member is interconnected with the top member via ahinge connection that provides pivoting movement of the movable closuremember between the open and closed positions. The hinge connection is inthe form of a hinge area of material located between the movable closuremember and the panel opening that is formed along with the frame and themovable closure member. The platform area of the frame is formed todefine a lip area that surrounds the panel opening, and the hinge areaof material is located between the lip area and the closure member. Inone form, the hinge area of material is at least in part defined by anunderlying protrusion defined by the interior panel during formation ofthe platform area and the movable closure member.

This aspect of the invention further contemplates a top member for usein closing an upper opening defined by a container and a method formanufacturing a reclosable top for a container, substantially inaccordance with the foregoing summary.

While the aspects of the present invention may be employed separately toprovide a container or package that has improved characteristics orfeatures compared to the prior art, it is contemplated that the variousaspects of the invention are particularly advantageous in combination todeliver significant advantages and benefits both to the manufacturer andto the consumer, in an efficient and cost effective manner.

Various other features, objects and advantages of the invention will bemade apparent from the following description taken together with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carryingout the invention.

In the drawings:

FIG. 1 is an isometric view of a container incorporating the variousaspects of the present invention;

FIG. 2 is an isometric topside view of a lid or top member for thecontainer of FIG. 1, showing the top member as molded and showing a sealmembrane in place over an opening that provides access to the interiorof the container, and further showing the movable closure member in theopen position;

FIG. 3 is an isometric underside view of the container top member ofFIG. 2;

FIG. 4 is a top plan view of the container top member of FIG. 2;

FIG. 5 is a cross sectional view along line 5-5 of FIG. 4;

FIG. 6 is an isometric topside view of the container top member of FIG.2, showing the seal membrane removed and further showing the movableclosure member in the open position in which the opening in the topmember is exposed to provide access to the interior of the container;

FIG. 7 is a top plan view of the container top member of FIG. 2, showingthe movable closure member in the closed position in which the openingin the top member is closed to prevent access to the interior of thecontainer;

FIG. 8 is a cross sectional view along line 8-8 of FIG. 7;

FIG. 9 is an isometric topside view of the container top member of FIG.2, showing the movable closure member in the closed position in whichthe opening in the top member is closed to prevent access to theinterior of the container;

FIG. 10 is an isometric view of a fusion ring incorporated in thecontainer top member of FIG. 2 and/or the bottom member of FIG. 13 foruse in bonding the top member to the upper edge of a container body orfor use in bonding the bottom member to the bottom edge of a containerbody;

FIG. 11 is an isometric view of the fusion ring of FIG. 10 incombination with a plastic panel incorporated in the top member, showingthe fusion ring and the panel prior to the molding of the frame of thetop member;

FIG. 12 is an isometric view of another embodiment of a fusion ringadapted to be incorporated in the container top member of FIG. 2 and/orbottom member of FIG. 13;

FIG. 13 is an isometric topside view of a bottom member for use informing the container of FIG. 1;

FIG. 14 is a cross sectional view along line 14-14 of FIG. 15;

FIG. 15 is a bottom plan view of the container bottom member of FIG. 13;

FIG. 16 is an isometric view of a container body, in the form of anextruded tube, for use in making the container of FIG. 1;

FIG. 17 is an isometric view of the container body of FIG. 16, showingthe container body captured between upper and lower seal members for usein forming the container body;

FIG. 18 is an isometric view of the container body of FIG. 16 capturedbetween the upper and lower seal members and positioned between a pairof mold sections for use in forming the container body;

FIG. 19 is a top plan view of the container forming mold sections ofFIG. 18 closed upon the seal members and the container body prior toforming the container body;

FIG. 20 is a cross sectional view along line 20-20 of FIG. 19;

FIG. 21 is a cross sectional view similar to FIG. 20, showing thecontainer body after forming within the mold sections;

FIG. 22 is an isometric view similar to FIG. 18, showing the containerbody after forming within the mold sections;

FIG. 23 is an isometric topside view showing the formed container body;

FIG. 24 is an isometric underside view of the container body of FIG. 23showing a bottom member secured to a bottom edge defined by thecontainer body;

FIG. 25 is an elevation view of the assembled container as in FIG. 1,showing the container top member secured to the top of the containerbody and the bottom member secured to the bottom of the container body;

FIG. 26 is a cross sectional view along line 26-26 of FIG. 25;

FIG. 27 is an enlarged segmented view within circle 27 of FIG. 26;

FIG. 28 is an enlarged segmented view within circle 28 of FIG. 26;

FIG. 29 is an isometric topside view of a blow molded or thermoformedcontainer body for use in forming a container in accordance with thepresent invention;

FIG. 30 is an isometric topside view of the container body of FIG. 29showing the top member of FIGS. 2-9 secured to the upper edge of thecontainer body;

FIG. 31 is front elevation view of the container and top member of FIG.30;

FIG. 32 is an isometric topside view showing an extruded tube containerbody and a bottom member secured to the bottom edge of the containerbody;

FIG. 33 is a bottom plan view of the bottom member secured to the bottomedge of the container body of FIG. 32;

FIG. 34 is a cross sectional view along line 34-34 of FIG. 33;

FIG. 35 is an enlarged segmented view within circle 35 of FIG. 34;

FIG. 36 is an isometric view of the extruded tube container body andbottom member of FIG. 32, captured between a lower holder and an upperseal member for use in forming the container body;

FIG. 37 is an isometric view of the extruded tube container body andbottom member of FIG. 32, captured between the lower holder and theupper seal member and positioned between a pair of mold sections for usein forming the container body;

FIG. 38 is a top plan view of the upper seal member of FIGS. 36 and 37and the container forming mold sections closed upon the container body;

FIG. 39 is a cross sectional view along line 39-39 of FIG. 38, showingthe container body prior to forming within the mold sections;

FIG. 40 is a cross sectional view similar to FIG. 39, showing thecontainer body after being formed within the mold sections;

FIG. 41 is an isometric view of the formed container body of FIG. 40captured between the lower holder and the upper seal member;

FIG. 42 is an isometric view of the formed container body of FIGS. 40and 41 after removal from between the mold sections;

FIG. 43 is an isometric view similar to FIG. 16, illustrating a doublewall container body for use in making a container in accordance with thepresent invention;

FIG. 44 is a top plan view of the container body of FIG. 43;

FIG. 45 is an isometric view of the container body of FIG. 43, showingthe ends of the container body crimped together in preparation forassembly into the container in accordance with the present invention;

FIG. 46 is a top plan view of the container body of FIG. 45;

FIG. 47 is a section view taken along line 47-47 or FIG. 46;

FIG. 48 is a section view similar to FIG. FIG. 26, showing the containerbody of FIGS. 43-47 incorporated into a container in accordance with thepresent invention;

FIG. 50 is a top plan view of tooling for producing formed containerbodies, for use in forming a container as shown in FIG. 1, in analternative molding process known as continuous vacuum forming; and

FIG. 50 is a section view taken along line 50-50 of FIG. 49.

DETAILED DESCRIPTION OF THE INVENTION

The following is a detailed description of the preferred embodiment ofthe invention. It is important to note that the invention is not limitedto the shapes, sizes and proportions shown in the figures and discussedin the following description. Even though the embodiments shown anddiscussed are in the form of round or cylindrical packages and packagecomponents, it is anticipated that other shapes such as square,rectangular, oval, triangular, and polygonal, etc. could be used.Likewise, it is anticipated that other features of the design, such asthe lid opening and mating closure, could also have a multitude ofshapes, sizes and proportions. The preformed containers shown are notrestrictive to the specific embodiment with which they are associated inthe figures.

This invention seeks to replace the more energy and/or materialintensive packages with packages which provide the same relative amountof product protection while consuming much less energy in theircomparative total life cycle. Additionally, the package seeks to provideimprovements or benefits not possible with current forms of packaging.These improvements relate both to the manufacturing processes as well asmore use-oriented benefits. While it may be possible to obtain packageswhich contain one or more of these improvements or benefits, our systemis the first to offer all of these benefits to the manufacturer and/orconsumer at one time, in a cost effective manner.

To be considered as possible replacements for traditional metal, doubleseamed ends, it is necessary for plastic closures to provide the sameproduct protection, food process compatibility and ease of containeraccess offered by traditional closures. Today, using the moldingtechnologies disclosed herein, it is possible to produce all-plasticclosures that meet the minimum criteria established by the traditionalclosures.

The features of a container lid or bottom cap that includes a frame madefrom a thermoplastic polymeric material, a pre-formed, pre-treated, andpre-die-cut, multi-layered, semi-rigid, high-barrier plastic panel and afusion ring made from an electro-magnetic, radio frequency, orultrasonic polymeric, fusible material suitable for bi-injectionmolding, and the process for the manufacture of the container lid andbottom cap, are disclosed in copending patent application serial numberPCT/US03/25713 filed Aug. 18, 2003 and entitled MULTI-COMPONENTPACKAGING SYSTEMS FOR SHELF STABLE FOODS AND BEVERAGES, the disclosureof which is hereby incorporated by reference.

The capability to mold multiple materials (in addition to insert moldingand in-mold heat-sealing) allows for plastic ends to be developed whichcan be designed to provide adequate keeping properties in terms of gasand moisture barriers. Additionally, the ends can be designed tothermally weld to the contacted surfaces of the container by the use ofultra-sonic, electro-magnetic or RF heating of the fusion bondingsystem. Heating of the bonding system by either of these means willraise the temperature of the fusion bonding material and the materialsit contacts to their fusion temperature. Once this temperature isachieved, the similar materials contained in both the container and theclosure exchange molecules at the interface of these adjacent articlesto be joined and a thermal/fusion weld is made. The preferred process ofinduction is not new but previously had required the insertion ofelectromagnetically and/or RF excitable or conductive materials such aswire, metal foil or a metal-powder filled gasket or liquid adhesivebetween the parts to be welded (U.S. Pat. Nos. 5,114,507; 6,258,312;3,620,875; 3,620,876; 4,201,306, all hereby incorporated by reference).

The electromagnetic and/or conductive materials, or RF responsivematerials, that may used in our fusion ring may include powders ofstainless steel, tin oxide, iron, carbon black, carbonaceous or othermaterials. The preferred material will include iron powder similar tothose described in expired U.S. Pat. Nos. 3,620,876 and 3,620,875 exceptthat any and all materials will be required to be acceptable for directfood contact by the U.S. Food and Drug Administration when the fusionring is to be used in a package containing human or non-human food. Thepreferred materials that meet these criteria include both a sponge ironpowder (FG 100) as manufactured by the Hoeganaes Company, Inc of Ramsey,N.J. or a carbonyl iron powder (Ferronyl) as produced by ISPTechnologies Inc. of Freehold, N.J. or other similar food grade ironpowders.

Containers may be made of polymeric materials typically used forpackaging and include materials such as polyethylene, polystyrene,polypropylene, polyester, polycarbonate, acrylonitrile-butydene-styrene,acrylic-terpolymers, nylon or polyvinyl-chloride as well as othermaterials used in the manufacture of packages.

Referring to FIG. 1, a container 100 in accordance with the presentinvention generally includes a container body 102 that defines aninterior and open top and bottom ends, in combination with a lid or topmember 104 secured to the upper end of container body 102, and a bottomcap or member 106 secured to the lower end of container body 102.Container 100 is adapted to contain solid or liquid products in anyflowable form, such as foods, drugs, chemicals and other products,including dry, semi-moist and liquid products.

Referring to FIGS. 2-9, top member 104 includes a frame 110, an interiorpanel 112, and a closure member 114. Frame 110 defines an outerperiphery that surrounds an outer edge defined by panel 112. Frame 110further includes a platform 116 that overlies a portion of panel 112 andis located inwardly of the outer periphery defined by frame 110.Platform 116 includes an opening 118 (FIG. 3). Top member 104 furtherincludes a removable seal member 120 that is secured to platform 116over opening 118. Seal member 120 is configured to be secured to theupper surface of platform 116 outwardly of opening 118, to provide anair-tight seal of opening 118.

Panel 112 of top member 104 is formed of a suitable pre-treated,multi-layered, semi-flexible, high-barrier thermoplastic material, as isknown in the art. Panel 112 is selected to have the desired gas,moisture barrier and physical properties required by the product orcommercial sterilization process of container 100. Panel 112 may beformed by die cutting from a sheet in a shape to match the shape offrame 110, and is formed to include a panel opening 122 defined by aperipheral edge. Panel 112 is further formed to define an outer raisedflange 124, and an angled ring section 126 located inwardly of outerflange 124. Panel 112 further includes a generally linear transverseprotrusion 128 located adjacent platform opening 118. Platform 112further includes a recess 130 defined by a sloped bottom wall 132 and anend wall 134. Recess 130 is located on panel 112 so as to be oppositeplatform opening 118 relative to protrusion 128.

Frame 110 of top member 104 includes a shoulder 138 that overlies flange124 of panel 112. A peripheral outer rim 140 extends upwardly fromshoulder 138. Below shoulder 138, frame 110 defines a channel 142 formedby an outer leg 144 and an inner leg 146. A fusion member, in the formof a fusion ring 148, is located within channel 142. Fusion ring 148 isconfigured so as to be located within the upper extent of channel 142between outer leg 144 and inner leg 146. Fusion ring 148 defines anupper surface that underlies panel flange 124 and is formed so as tohave a similar outside diameter as the outside diameter of panel 112.The properties and function of fusion ring 148 are set forth in theabove-referenced copending application serial number PCT/US03/25713.

Platform 116 and closure member 114 are formed integrally with frame110. Platform 116 generally defines an upper wall 150 that overlies theupper surface of a portion of panel 112 about panel opening 122.Platform 116 defines an inner edge 152. Platform 116 occupies the areabetween inner edge 152 and shoulder 138, so as to overlie the portion ofpanel 112 in which panel opening 122 is formed. Platform 116 furtherincludes a depending peripheral lip 154 that surrounds and encapsulatesthe edge of panel 112 that defines panel opening 122, and the inner edgeof platform lip 154 defines platform opening 118. Platform lip 154 isconfigured so as to surround the area of panel 112 adjacent panelopening 122, with a portion of lip 154 being located below panel 112 anda portion of lip 154 being located inwardly of the edge of panel 112defining panel opening 122. In the event panel 112 includes an EVOHlayer, lip 154 prevents the EVOH layer from being exposed to hightemperature products, which is restricted under current FDA regulations.

Closure member 114 of top member 104 is formed in an open position, asshown in FIGS. 1-6. Closure member 114 includes a generally planarclosure wall 158, in combination with a peripheral closure rim 160having a shape that matches that of platform opening 118. Closure wall158 is joined to platform upper wall 150 via a hinge section 162 thatoverlies panel protrusion 128. Hinge section 162 provides movement ofclosure member 114 between an open position and a closed position, in amanner to be explained. In addition, closure member 114 includes a tab164 that is located over panel recess 130 when closure member 114 is inthe open position. A flexible hinge 166 is interposed between tab 164and closure wall 158 of closure member 114.

FIG. 10 illustrates fusion ring 148. In the illustrated embodiment,fusion ring 148 is circular in shape. It is understood, however, thatfusion ring 148 may have any other desired shape according to theconfiguration of the container into which fusion ring 148 isincorporated. Fusion ring 148 includes opposed pairs of passages 170, inthe form of depressions or recesses that extend below the upper edge offusion ring 148 and throughout the width of fusion ring 148. FIG. 12illustrates an alternative fusion ring 148′ formed of separate ringsections 172 a, 172 b, 172 c and 172 d, which are separated by spaces orgaps 174 to provide passages between the inner and outer surfaces offusion ring 148′.

FIG. 11 shows panel 112 and fusion ring 148 prior to molding of panel112 and fusion ring 148 into top member 104. Flange 124 of panel 112 ispositioned so as to rest on the upper surface of fusion ring 148.Passages 170 communicate between the inner and outer surfaces of fusionring 148, and panel flange 124 overlies passages 170.

Representatively, the process for the manufacture of top member 104 isas follows. A first mold section and a second mold section areconfigured to form a cavity for molding of fusion ring 148. After fusionring 148 is formed, the second mold section is removed and panel 112 isplaced onto fusion ring 148, as shown in FIG. 11, such that flange 124of panel 112 contacts and rests on the upper surface of fusion ring 148.A third mold section is then positioned over the first mold section, soas to enclose fusion ring 148 and panel 112. The first and third moldsections have cavities that correspond in shape to frame 110 includingplatform 116 and closure member 114. Thermoplastic polymeric material ina flowable state is then injected into the mold cavities so as to formthe various contours, features and surfaces of frame 110, platform 116and closure member 114 as shown and described. Passages 170 in fusionring 148 enable the thermoplastic material to flow through fusion ring148, to form the areas of frame 110 that underlie panel 112. In theevent fusion ring 148′ is used, the spaces or gaps 174 between thesection 172 a-172 d allow material to form the areas of frame 110 thatunderlie panel 112. Top member 104 is then removed or ejected from themold sections in any satisfactory manner. Seal member 120 may be appliedto platform 116 to enclose platform opening 118 either before or aftertop member 104 is released or ejected from the mold.

When seal member 120 is removed, so as to expose platform opening 118,closure member 114 may be employed to selectively close platform opening118. FIGS. 7-9 show the closed position of closure member 114, in whichclosure member 114 closes platform opening 118. To move closure member114 from the open position to the closed position, the user grasps tab164 of closure member 114 and applies an upward force to closure member114. Recess 130 in panel 112 facilitates such manual engagement of tab164 by the user. Application of the upward force to closure member 114functions to pivot closure member 114 about hinge section 162. The usercontinues such pivoting movement of closure member 114 away from theopen position, so that closure member rim 160 is moved toward platformopening 118 by application of a downward force to closure member 114.The user continues such pivoting movement of closure member 114 untilclosure member rim 160 is engaged within platform opening 118. Tab 164pivots about hinge 166, so as to allow tab 164 to extend upwardly whenclosure member 114 is in the closed position. In this manner, tab 164can be subsequently used to facilitate movement of closure member 114from the closed position back toward the open position, when it is onceagain desired to expose platform opening 118. It is also contemplatedthat tab 164 may be formed without hinge 166, so that the angularposition of tab 164 on closure member 114 remains fixed. In thisembodiment, rim 140 of top member 104 is preferably provided with arecess or gap within which tab 164 is received when closure member 104is pivoted to the open position.

During manufacture, a release agent is coated or printed onto the uppersurface of panel 112 that underlies closure member 114. In this manner,when closure member 114 is made by injecting the flowable thermoplasticmaterial onto and about panel 112, the material that forms closuremember 114 does not adhere to or otherwise bond with the underlyingmaterial of panel 112, to enable closure member 114 to easily be movedfrom its open position toward its closed position.

FIGS. 13-15 illustrate bottom member 106 of container 100, which isgenerally similar in construction to top member 104. Bottom member 106includes a frame 178 having a shoulder 180 and an upwardly extending rim182 (which extends downwardly when bottom member 106 is secured tocontainer 100). Frame 178 further includes a channel 184 defined byshoulder 180 in combination with an outer leg 186 and an inner leg 188.A fusion ring 200 is contained within the upper extent of channel 184.

Bottom member 106 further includes an interior panel 202 locatedinwardly of frame 178. Panel 202 defines an outer peripheral edge thatis surrounded by frame 178. Panel 202 may be formed with undulations204, which, in combination with the material choice and thickness, areconfigured to encourage any package deformation caused by an increase ordecrease in the internal pressure of the package to occur in panel 202.

Panel 202 is constructed similarly to panel 112, e.g. by die cutting amulti-layered, semi-rigid, high-barrier plastic panel to the desiredshape. Bottom member 106 is also constructed similarly to top member104, by first molding fusion ring 200 in first and second mold sectionshaving a cavity shaped so as to correspond to the final desired shape offusion ring 200. Fusion ring 200 is constructed similarly to fusion ring148, including passages, gaps or spaces that establish communicationbetween the inner and outer surfaces of the fusion ring. After fusionring 200 is formed, the second mold section is removed and lower panel204 is placed on fusion ring 200 so that the outer edge of lower panel204 rests on the upper surface of fusion ring 200. A third mold section,in conjunction with the first mold section, fusion ring 200 and panel202 then forms a cavity for frame 178. Flowable thermoplastic materialis then injected into the cavity to form frame 178, and the passages infusion ring 200 below panel 202 enable the thermoplastic material toflow through fusion ring 200 below lower panel 204, to provide completemolding of the areas of frame 178 located inwardly of fusion ring 200and below lower panel 204. Bottom member 106 is then released, ejectedor otherwise removed from the mold.

FIG. 16 illustrates container body 102 prior to container body 102 beingformed to a contoured shape as shown in FIG. 1. Container body 102 ispreferably in the form of an extruded plastic member having a desiredlength according to the final configuration of container 100. Containerbody 102 is in the form of a tubular member defining an interior that isaccessible through a top opening 210 and a bottom opening 212. Containerbody 102 may be formed of any satisfactory material, and may be formedof one or more layers, depending upon the requirements of container 100.

FIGS. 17-23 illustrate the manner in which container body 102 is formedto the final desired shape. To form container body 102, an upper holderor seal member 214 is engaged with the upper end of container body 102so as to overlie and enclose upper opening 210, and a lower holder orseal member 216 is engaged with the lower end of container body 102 soas to overlie and enclose bottom opening 212. One of seal members 214and 216, such as seal member 214, includes a pressurizing passage 218.

Container body 102 is then converted to a deformable state, such as byexposure to a radiant heat source, to soften the material of containerbody 102 to a pliable state. The heated container body 102 is thenpositioned between a pair of mold sections 220 a, 220 b, which havecontoured inner mold surfaces 222 a, 222 b, respectively, that cooperateto define an internal cavity having a shape that corresponds to thefinal desired shape of container body 102 when mold sections 220 a, 220b are moved together. Mold sections 220 a, 220 b are then closed ontoupper seal member 214, lower seal member 216 and container body 102, asshown in FIGS. 19 and 20. Mold sections 220 a, 220 b representativelyhave rims or shoulders 224 a, 224 b, which are received within recessesdefined by seal members 214, 216 and which engage the upper and loweredges of container body 102. With this construction, top and bottomopenings 210, 212, respectively, of container body 102 are maintained inthe original shape and sealed.

A source of pressurized fluid, such as pressurized gas, is then broughtinto communication with seal member passage 218, as shown in FIG. 20.Representatively, the source of pressurized gas may be an air blow tube226. Pressurized air is then applied through blow tube 226 and passage218 to the interior of container body 102. Such introduction ofpressurized air causes the pliable material of the walls of containerbody 102 to deform outwardly and into contact with the mold surfaces 222a, 222 b of mold sections 220 a, 220 b, respectively, thus forming thedesired shape of container body 102. The formed container body 102 isthen cooled within the mold sections 220 and/or by air after moldsections 220 a, 220 b are opened. The cooled and formed container body102 is then removed from upper and lower seal members 214, 216,respectively, to provide container body 102 having a shape as shown inFIG. 23.

It is understood that the specific shape of container body 102 as shownin the drawings is representative, and that any other shape of containerbody 102 may be provided as desired.

Alternatively, it is contemplated that the pliable material of the wallsof container body 102 may be deformed outwardly into contact with themold surfaces 222 a, 222 b of mold sections 220 a, 220 b, respectively,using a vacuum forming process. In this case, negative air pressure isintroduced in the space between the walls of container body 102 and moldsurfaces 222 a, 222 b, such as through vacuum ports formed in moldsections 220 a, 220 b that open onto mold surfaces 222 a, 222 b. Suchintroduction of negative air pressure causes the walls of container body102 to deform outwardly into contact with mold surfaces 222 a, 222 b, toform container body 102 to the desired shape. Non-pressurized air isdrawn through tube 226 and passage 218 into the interior of containerbody 102, to add to the volume of air required as the interior volume ofcontainer body 102 expands during the vacuum forming operation. The airintroduced into the interior of container body 102 may also bepressurized, in order to assist in the vacuum forming of container body102.

FIG. 24 shows bottom member 106 secured to the lower end of containerbody 102, in a manner to be explained. FIG. 25 shows both top member 104and bottom member 106 secured to the upper and lower ends, respectively,of container body 102, to form container 100.

FIG. 27 illustrates the manner in which the upper end of container body102, shown at 230, is secured to top member 104. Similarly, FIG. 28shows the manner in which the lower end of container body 102, shown at232, is engaged with bottom member 106.

In order to produce container 100, bottom member 106 is first secured tolower end 232 of container body 102. To accomplish this, container bodylower end 232 is positioned within upwardly facing channel 184 definedby frame 178 of bottom member 106, so that the lower edge of lower end232 rests on fusion ring 200. Outer leg 186 and inner leg 188 of channel184 guide lower end 232 into contact with the exposed surface of fusionring 200. Fusion ring 200 is then exposed to an electromagnetic or radiofrequency field while a downward force is applied to container body 102.As disclosed in copending application Serial No. PCT/US/25713 filed Aug.18, 2003, such exposure of fusion ring 200 to the electromagnetic and/orRF field functions to permanently and hermetically fuse bottom member106 to lower end 232 of container body 102, due to the heating of fusionring 200 to a semi-molten state by the non-contact, electromagneticand/or RF excitement of the metallic and/or carbonaceous fillerscontained within fusion ring 200, to embed the lower portion ofcontainer body lower end 232 into the semi-molten fusion ring 200. Afterbottom member 106 is applied and cooled, container body 102 can befilled with product in a manner as is known in the art.

After container body 102 is filled, top member 104 is applied to upperend 230 of container body 102. This is accomplished by first droppingtop member 104 onto upper end 230 of container body 102 so that upperend 230 is received within channel 142. Legs 144 and 146 of channel 142function to guide top member 104 onto upper end 230 of container body102, until the upper edge of upper end 230 contacts the downwardlyfacing surface of fusion ring 148. As before, fusion ring 148 is thenexposed to an electromagnetic and/or RF field while a downward force isapplied to top member 104. Such exposure of fusion ring 148 to theelectromagnetic and/or RF field functions to heat fusion ring 148 to asemi-molten state by the non-contact electromagnetic and/or RFexcitement of the metallic and/or carbonaceous fillers contained withinfusion ring 148, to embed the upper portion of container body upper end230 into the semi-molten fusion ring 148. Top member 104 is thuspermanently and hermetically fused to the top rim of container body 102.After filling and application of top member 104, the contents ofcontainer 100 can be accessed by removing seal member 120. In apreferred form, seal member 120 includes a pull tab portion that extendspast platform edge 152, which facilitates manual engagement with sealmember 120. As noted previously, container 100 can be convenientlyreclosed by moving closure member 114 from the open position to theclosed position.

Rim 140 of top member frame 110, in combination with channel 142,provide controlled stacking of top members 104, one on top of the other,for improved handling of top members 104 prior to application to the topof container body 102. In addition, rim 182 of bottom member frame 178is configured to nest with rim 140 of top member frame 110, to providecontrolled stacking of containers 100 on top of one another. Shoulder138 of top member frame 110 provides a seating surface for rim 182 ofbottom member frame 178. Further, rims 182 and 140 are configured tocontrol lateral movement between stacked containers.

Inner leg 146 of channel 142 and inner leg 188 of channel 184 are ofsufficient length to contain any melted residue from respective fusionrings 148, 200, in order to minimize contact between the product and theelectromagnetic or RF responsive polymeric, fusible material of thefusion rings. The outer legs 144, 186 of channels 142, 184,respectively, may be shorter, longer or of equal length relative to theinner legs, depending upon the aesthetic and any additional functionalrequirements such as to facilitate application to the container body.For example, in the event the outer leg is longer than the inner leg,the top or bottom member can be presented to the container at an angle.As the top or bottom member is lowered, the outer leg catches onto therim of the moving container, to extract the member from a feeder troughand to guide the member into place on top of the container rim.

FIGS. 29-31 illustrate an alternative container body, shown at 236,which is adapted to be closed using top member 104 in accordance withthe present invention. In this embodiment, container body 236 may beblow molded, thermoformed, or formed in any other satisfactory manner,so that container body 236 has an integral bottom wall. With thisconstruction, bottom member 106 is not employed, and the open upper endof container body 236 is closed using top member 104 in the same manneras described above. This construction provides a reclosable top memberfor a container body of this type.

FIGS. 32-42 illustrate an alternative construction that is contemplatedas being within the scope of the present invention, and like characterswill be used where possible to facilitate clarity.

In this construction, a bottom member 106 a is applied to the lower endof a container body 102 a before container body 102 a is formed to thefinal desired shape. In this embodiment, bottom member 106 a defines anouter leg 186 a of substantially greater height than inner leg 188 a.The bottom end of container body 102 a is fused to fusion ring 200 a asdescribed above.

After bottom member 106 a is applied to the bottom end of container body102 a, upper holder or seal member 214 a is engaged with the upper endof container body 102 a and bottom member 106 a is received within acavity or recess defined by a lower holder 236, as shown in FIG. 36.Referring to FIG. 37, mold sections 238 a, 238 b are moved intoengagement with upper seal member 214 a and lower holder 236. Moldsections 238 a, 238 b define inner mold surfaces 240 a, 240 b thatcooperate to define a cavity corresponding in shape to the final desiredshape of container body 102 a. Container body 102 a is then heated sothat its walls are in a pliable state, and pressurized air is thenapplied to the interior of container body 102 a. The walls of containerbody 102 a are then forced outwardly, as shown in FIG. 40, to conform tothe mold surfaces 240 a, 240 b defined by mold sections 238 a, 238 b,respectively. In this embodiment, outer leg 186 a of channel 184 a has acontour that forms a part of the surface against which the walls ofcontainer body 102 a are forced, so as to partially define the shape ofcontainer body 102 a. Container body 102 a is then cooled, and moldsections 238 a, 238 b are removed as shown in FIG. 41. Upper seal member214 and lower holder 236 are then removed, to provide the formedcontainer body 102 a and bottom member 106 a as shown in FIG. 42.Container body 102 a can then be filled with product and a top memberapplied as before so as to enclose and seal the container body.

FIGS. 43-48 illustrate an alternative container body, shown at 248,which is adapted to be used in forming a container 100 in accordancewith the present invention. In this embodiment, container body 248 has adouble wall construction, including an inner wall 250 and an outer wall252. A series of ribs 254 extend between and interconnect inner wall 250and outer wall 252. Ribs 254 cooperate with inner wall 250 and outerwall 252 to define a series of air chambers 256, which extend throughoutthe length of container body 248. Representatively, container body 248may be formed in an extrusion process in which inner wall 250, outerwall 252 and ribs 254 are formed simultaneously, although it isunderstood that container body 248 may be formed in any othersatisfactory process. Either or both of inner wall 250 and outer wall252 may have a multi-layer construction including a barrier propertieslayer, if desired. Container body 248 is cut to a desired length afterthe extrusion process, according to the desired final configuration ofthe container 100.

After being formed as described above, container body 248 is preparedfor assembly into container 100 by crimping or otherwise sealing theends of container body 248 as shown in FIGS. 45-47, to seal air chambers256. To accomplish this, container body 248 is held between an upperholder and a lower holder, each of which has a plug or other member thatfits into the interior of container body 248 at its upper and lowerends, respectively. Each plug conforms to the shape of the interior ofcontainer body 248 at its associated end of container body 248. Exteriorcrimping devices are then engaged with the ends of container body 248,and close upon outer wall 252 to move outer wall 252 toward inner wall250 at the ends of container body 248. The crimping process alsoinvolves heating of the ends of container body 248, so that the materialof outer wall 252 and inner wall 250 merges together to form an upperrim 258 and a lower rim 260. The formation of upper rim 258 and lowerrim 260 in this manner is such that rims 258, 260 enclose the upper andlower ends, respectively, of air chambers 256. After the ends ofcontainer body 248 are crimped together and sealed as described above,container body 248 is utilized in the same manner as container body 102described above, to produce a container 262 (FIG. 48) that has a similaroverall construction to container 100. That is, a lid or top member 104is applied to upper rim 258 and a bottom cap or member 106 is applied tolower rim 260, in the same manner as described above with respect to theapplication of top and bottom members 104, 106, respectively, to theupper and lower ends, respectively, of container body 102 With thisconstruction, container 262 has the same advantages over the prior artas described above with respect to container 100, and also includes aninsulating feature provided by the presence of sealed air chambers 256within container body 248.

In an alternative forming method, known as continuous vacuum forming, apolymeric tube is continuously extruded and travels between sets of moldhalves. A system of this type is schematically illustrated at 300 inFIGS. 49 and 50. In this forming method, moving tooling in the form of acontinuous or sequential series of mold halves 302 are mounted to spacedapart runs of a means of conveyance, such as continuous belts trainedabout pulleys or sprockets, in a manner as is known. An extruded tube ispositioned and advanced between the mold halves 302, which are movedtogether onto the pliable polymeric material of the extruded tube. Aninternal sizing mandrel or sleeve 304 is carried within the interior ofthe continuously extruded polymeric tube. The sizing mandrel or sleeve304 is connected to the end of the die and provides a low pressure seal,to allow the use of internal positive pressure in addition to externalnegative pressure to facilitate the forming of the container walls. Oncethe container walls are formed and cooled, the containers 102 areseparated (cut) from each other. A system such as this is shown anddescribed in Held, Jr. U.S. Pat. No. 3,837,517 and in Kemerer et al U.S.Pat. No. 5,167,781, the disclosures of which are hereby incorporated byreference.

Crimping can also be accomplished in the continuous vacuum formingsystem 300 by having the moving tooling press the pliable polymericmaterial of the tube against the internal sizing mandrel or sleeve 304that is carried within the interior of the continuously extrudedpolymeric tube.

While the invention has been shown and described with respect tospecific embodiments, it is understood that various alternatives andmodifications are possible and are contemplated as being within thescope of the present invention. For example, and without limitation, thecontainer top member, body and bottom member may be a variety of shapes,including non-circular shapes, in addition to the circular shapes asshown in the drawing figures. Likewise, the top member of the containermay have a variety of shapes for the platform opening and the rim of theclosure member, in addition to the specific shape as shown anddescribed. Further, while mating rims have been shown for providing acontainer stacking feature, it is contemplated that any othersatisfactory mating stacking feature could be designed into thecontainer bottom member which would eliminate the need for the rimfeature on the container top member, in which the case the frame of thetop member can be flat. Likewise, appropriate stacking features can bedesigned into the container top member, which can therefore eliminatethe need for the rim feature on the container bottom member, so as toenable the bottom of the frame to be flat. While the fusion ring hasbeen shown as being formed either in segments or with channels, it iscontemplated that any other satisfactory conduit-type arrangement may beincorporated into the fusion ring so as to allow for the flow through ofthermoplastic material during injection molding of the frame about thefusion ring. In addition, the top member can be applied to a containerformed by a method other than the container body and bottom cap type asdescribed. Other container types can also be thermoformed or blow moldedwith a continuous bottom and a flangeless rim at the top. Further, thecontainer body may be simply the extruded tubular member, without beingdeformed to the shape as shown and described.

While the invention has been shown and described primarily in connectionwith the use of electromagnetic or RF energy to heat the fusion memberto bond the top and/or bottom member to the container body, it is alsocontemplated that any other type of energy may be employed in order toexcite an internal fusion member in a non-contact manner to bond the topand/or bottom member to the container body.

It is also contemplated that the container may be constructed so as toeliminate the reclosable feature provided by closure member 114. In thisconstruction, top member 104 is formed with platform 116 so as tooverlie a portion of panel 112 and to enclose the edge of panel opening122, and closure member 114 is eliminated.

In addition, the container may be filled through the platform openingafter the container lid is secured to the container. In this case, thehigh barrier peel-away seal member is applied after filling. Further, itis also contemplated that the container top member can be secured to thebody first, with the container then being filled with product and thebottom cap applied thereafter, in a reverse series of steps to thoseshown and described in FIGS. 33-42.

It is also contemplated that the container may be fitted with anoptional, removable snap-on overcap to serve a variety of purposes. Theouter wall of the overcap is designed to fit over the outside leg of thecontainer lid. A bead on the inside surface of the outer wall of theovercap locates below the outside edge of the outer leg of the containerlid. The overcap also includes a rim to act in the same manner as therim of the frame. In a case such as this, an overcap with a rim may beused to eliminate the need for a rim on the frame of the container topmember. The overcap acts as a protective cover for the package or forthe remaining contents of the package after the package has been openedand the tear-away seal member has been removed and discarded. Optionalopenings in the overcap may serve as a means for venting heat and steamfrom the package during microwaving or cooking of the contents of thepackage.

Various alternatives and embodiments are contemplated as being withinthe scope of the following claims particularly pointing out anddistinctly claiming the subject matter regarded as the invention.

1. A storage container, comprising: a container body having one or moresides, an upper edge defining an upper opening, and a bottom; and a topmember secured to the upper edge and configured to enclose the upperopening, wherein the top member includes an interior panel having apanel opening; a removable seal member secured to the interior panel soas to enclose the panel opening; and a movable closure member carried bythe top member, wherein the movable closure member is interconnectedwith the top member so as to provide movement of the closure memberbetween an open position for exposing the panel opening when theremovable seal member is removed, and a closed position in which themovable closure member overlies and closes the panel opening. 2.(canceled)
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